Composite ultrasonic material applicators with individually addressable micro-applicators and methods of use thereof

ABSTRACT

A method of controlling application of at least one material to a substrate is provided. The method includes configuring at least one array having a plurality of micro-applicators such that a subset of the micro-applicators is individually addressable to apply the at least one material to the substrate. Individually addressing the subset of micro-applicators provides control of a pattern width of a coating applied to a substrate, control of a flow rate of the material applied to the substrate, control of an angle of application of the material to the substrate, control of which and how many materials are applied to the substrate, and combinations thereof.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S. provisional application No. 62/624,013 filed on Jan. 30, 2018. The disclosure of the above application is incorporated herein by reference

FIELD

The present invention relates to the painting of vehicles, and more particularly to methods and equipment used in high volume production to paint the vehicles and components thereof.

BACKGROUND

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Painting automotive vehicles in a high volume production environment involves substantial capital cost, not only for application and control of the paint, but also for equipment to capture overspray. The overspray can be up to 40% of the paint that exits an applicator, or in other words, to 40% of the paint that is purchased and applied is wasted (i.e. the transfer efficiency is ˜60%). Equipment that captures overspray involves significant capital expenses when a paint shop is constructed, including large air handling systems to carry overspray down through a paint booth, construction of a continuous stream of water that flows under a floor of the paint booth to capture the overspray, filtration systems, and abatement, among others. In addition, costs to operate the equipment is high because air (flowing at greater than 200K CFM) that flows through the paint booths must be conditioned, the flow of water must be maintained, compressed air must be supplied, and complex electrostatics are employed to improve transfer efficiency.

With known production equipment, paint is atomized by rotating bells, which are essentially a rotating disk or bowl that spins at about 20,000-80,000 rpms. The paint is typically ejected from an annular slot on a face of the rotating disk and is transported to the edges of the bell via centrifugal force. The paint then forms ligaments, which then break into droplets at the edge of the bell. Although this equipment works for its intended purpose, various issues arise as a result of its design. First, the momentum of the paint is mostly lateral, meaning it is moving off of the edge of the bell rather than towards the vehicle. To compensate for this movement, shaping air is applied that redirects the paint droplets towards the vehicle. In addition, electrostatics are used to steer the droplets towards the vehicle. The droplets have a fairly wide size distribution, which can cause appearance issues.

These issues of overspray, transfer efficiency, and paint uniformity, among other issues related to the painting of automotive vehicles or other objects in a high volume production environment, are addressed by the present disclosure.

SUMMARY

In one form of the present disclosure, a method of controlling application of at least one material (also referred to herein as “material(s)”) to a substrate is provided. The method comprises configuring at least one array having a plurality of micro-applicators, wherein each of the plurality of micro-applicators has a plurality of apertures through which the material(s) is ejected and at least a subset of the micro-applicators is individually addressable to apply the material(s) to the substrate. In some aspects of the present disclosure, the subset of micro-applicators is switched on and off to vary at least one of a pattern width of the material(s) onto the substrate and a flow rate of the material(s) onto the substrate. In the alternative, or in addition to, a plurality of materials is ejected from the plurality of micro-applicators. The plurality of materials may include different coating materials. For example, the plurality of materials may include a primer material, a basecoat material, a clearcoat material, and the like. In some aspects of the present disclosure, at least one coating material is applied to a previously applied coating material before the previously applied coating material is fully cured.

In some aspects of the present disclosure, a first subset of micro-applicators ejects a bulk basecoat material and a second subset of micro-applicators ejects a metallic flake material. In other aspects of the present disclosure, a first subset of micro-applicators ejects a rheological additive while a second subset of micro-applicators ejects a paint material and the rheological additive is mixed with the paint material during transport to the substrate. In still other aspects of the present disclosure, a plurality of paint colors is ejected from the plurality of micro-applicators. For example, in one aspect of the present disclosure, a first subset of micro-applicators ejects a first color and a second subset of micro-applicators ejects a second color different from the first color. Also, the plurality of paint colors may be ejected at different times and/or different angles.

In some aspects of the present disclosure, a first subset of micro-applicators is positioned on a first plane and a second subset of micro-applicators is positioned on a second plane different than the first plane. Also, the second plane may or may not be parallel to the first plane.

In some aspects of the present disclosure the substrate is a vehicle body component and the material(s) is (are) applied as a paint, an adhesive or a sealant.

In another form of the present disclosure, a method of controlling application of material(s) to a surface of a vehicle includes configuring at least one array of a plurality of micro-applicators comprising a first subset of micro-applicators and a second subset of micro-applicators different than the first subset of micro-applicators. Each of the plurality of micro-applicators has a plurality of apertures through which the material(s) is ejected and the first subset of micro-applicators and the second set of micro-applicators are individually addressable to apply the material(s) to the surface of the vehicle. In some aspects of the present disclosure, the first subset of micro-applicators and the second subset of micro-applicators are switched on and off to vary at least one of a pattern width, a flow rate of the material(s), and the number of materials applied to the surface of the vehicle. For example, in some aspects of the present disclosure, a first material is ejected from the first subset of micro-applicators and a second material different than the first material is ejected from the second subset of micro-applicators.

In still another form of the present disclosure, a material applicator for controlling application of material(s) to a substrate is provided. The material applicator includes an array of micro-applicators comprising a first subset of micro-applicators and a second subset of micro-applicators different than and individually addressable from the first subset of micro-applicators. Each of the micro-applicators comprises a micro-applicator plate, a plurality of apertures extending through the micro-applicator plate, and a reservoir in fluid communication with the plurality of apertures. At least one transducer is in mechanical communication with and configured to ultrasonically vibrate each of the micro-applicator plates. The material applicator is configured to apply the material(s) to a substrate from the first subset of micro-applicators independently from the second subset of micro-applicators. In some aspects of the present disclosure, the first subset of micro-applicators is positioned on a different plane than the second subset of micro-applicators.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:

FIG. 1 is a planar view of an exemplary paint spray system according to the teachings of the present disclosure;

FIG. 2A schematically depicts an exemplary view of an array of micro-applicators according to the teachings of the present disclosure;

FIG. 2B schematically depicts a side cross-sectional view of section 2B-2B in FIG. 2A;

FIG. 2C schematically depicts a side cross-sectional view of section 2C-2C in FIG. 2A;

FIG. 3A schematically depicts an exemplary view of an array of micro-applicators according to the teachings of the present disclosure;

FIG. 3B schematically depicts a side cross-sectional view of section 3B-3B in FIG. 3A;

FIG. 3C schematically depicts a side cross-sectional view of section 3C-3C in FIG. 3A; and

FIG. 4 is a flow diagram illustrating a method of controlling application of at least one material to a substrate according to the teachings of the present disclosure.

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Examples are provided to fully convey the scope of the disclosure to those who are skilled in the art. Numerous specific details are set forth such as types of specific components, devices, and methods, to provide a thorough understanding of variations of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed and that the examples provided herein, may include alternative embodiments and are not intended to limit the scope of the disclosure. In some examples, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The present disclosure provides a variety of devices, methods, and systems for controlling the application of paint to automotive vehicles in a high production environment, which reduce overspray and increase transfer efficiency of the paint. It should be understood that the reference to automotive vehicles is merely exemplary and that other objects that are painted, such as industrial equipment and appliances, among others, may also be painted in accordance with the teachings of the present disclosure. Further, the use of “paint” or “painting” should not be construed as limiting the present disclosure, and thus other materials such as coatings, primers, sealants, cleaning solvents, among others, are to be understood as falling within the scope of the present disclosure.

Generally, the teachings of the present disclosure are based on a droplet spray generation device in which a perforate membrane is driven by a piezoelectric transducer. This device and variations thereof are described in U.S. Pat. Nos. 6,394,363, 7,550,897, 7,977,849, 8,317,299, 8,191,982, 9,156,049, 7,976,135, 9,452,442, and U.S. Published Application Nos. 2014/0110500, 2016/0228902, and 2016/0158789, which are incorporated herein by reference in their entirety.

Referring now to FIG. 1, a paint spray system 2 for painting a part P using a robotic arms 4 is schematically depicted. The robotic arm 4 is coupled to at least one material applicator 10 and a rack 5. A material source 8 (e.g., a paint source) is included and includes at least one material M (materials M₁, M₂, M₃, . . . M_(n) shown in FIG. 1; also referred to herein simply as “material M” or “material(S)”). In some aspects of the present disclosure the material M includes different paint materials, different adhesive materials, different sealant materials, and the like. The arm 4 moves according to xyz coordinates with respect to rack 4 such that the material applicator 10 moves across a surface (not labeled) of the part P. Also, a power source 6 is configured to supply power to arm 4 and rack 5. Arm 4 and rack 5 are configured to supply material M from the material source 8 to the material applicator 10 such a coating is applied to the surface of the part P. While FIG. 1 schematically depicts the paint spray system 2 having a single robotic arm 4, it should be understood that paint spray systems with more than one robotic arm 4 are included within the teachings of the present disclosure.

Referring now to FIGS. 2A through 2C, the material applicator 10 according to the teachings of the present disclosure is schematically shown. In one form of the present disclosure, the material applicator 10 includes an array plate 100 with an applicator array 102 comprising a plurality of micro-applicators 110. In some aspects of the present disclosure, the array plate 100 lies on single plane. In other aspects of the present disclosure, the array plate 100 does not lie on a single plane as discussed in greater detail below.

In some aspects of the present disclosure, the array plate 100 with the applicator array 102 is positioned within a housing 140. Each of the micro-applicators 110 comprises a plurality of apertures 112 through which a material M is ejected such that atomized droplets 3 of the material are provided as schematically depicted in FIG. 2B. Particularly, each of the micro-applicators 110 has a micro-applicator plate 114 with the plurality of apertures 112 extending through the micro-applicator plate 114. Also, each of the micro-applicators 110 may include a transducer 120, a frame 130 and a material inlet 138. The transducer 120 is in mechanical communication with the micro-applicator plate 114 such that activation of the transducer 120 ultrasonically vibrates the micro-applicator plate 114 as schematically depicted by the horizontal (z-direction) double-headed arrows in FIG. 2B. The frame 130 includes a back wall 134 and at least one sidewall 132 such that a reservoir 136 for containing the material M is provided between the back wall 134 and the micro-applicator plate 114. The inlet 138 is in fluid communication with reservoir 136 and the material source 8 (FIG. 1) such that the material M can flow from the material source 8, through inlet 138 and into reservoir 136.

In operation, material M flows through the inlet 138 into the reservoir 136. Surface tension of material M results in material M not flowing through the apertures 112 of the micro-applicator plate 114 unless transducer 120 is activated and vibrates as schematically depicted in FIG. 2B. That is, when transducer 120 is activated and vibrates, material M is ejected through and/or from the plurality of apertures 112 as atomized droplets 3. In some aspects of the present disclosure the atomized droplets 3 have an average droplet diameter between 5 micrometers (μm) and 100 μm, for example between 10 μm and 75 μm, between 10 μm and 50 μm, or between 20 μm and 40 μm.

As schematically depicted in FIG. 2B, the atomized droplets 3 travel or propagate in a direction generally normal to the micro-applicator plate 114, i.e., generally parallel to a micro-applicator axis 2. As the material M is ejected through and/or from the plurality of apertures 112 a stream 5 of atomized droplets 3 is provided by each of the plurality of apertures 112 and a coating C on the surface(s) s′ of a substrate S is provided. While FIG. 2B schematically depicts the stream 5 of atomized droplets 3 propagating on the micro-applicator axis 2, it should be understood that the atomized droplets 3 propagate diffusely from the plurality of apertures 112 and the stream 5 may be angled relative to the micro-applicator axis 2. It should also be understood that other flow configurations of the material M flowing into and out of the reservoir 136 are included in the teachings of the present disclosure in addition to material M entering reservoir 136 through inlet 138 and exiting reservoir 136 through apertures 112.

Referring particularly to FIG. 2C, the micro-applicators 110 are positioned and aligned on a single plane 152. Also, the micro-applicators 110 are arranged in a plurality of subsets 150 n (n=1, 2, . . . ) such that at least one subset 150 n is individually addressable. For example, FIG. 2C schematically depicts three subsets of micro-applicators 110: subset 150 ₁, subset 150 ₂, and subset 150 ₃. The subset 150 ₁ includes the three middle micro-applicators 110 shown in FIG. 2C, the subset 150 ₂ includes the two outer micro-applicators 110, and the subset 150 ₃ includes the three micro-applicators 110 on the right hand side (+x-direction) of the array plate 100. As shown in FIG. 2C, one subset of micro-applicators (e.g., subset 150 ₃) can include one or more micro-applicators 110 from other subsets (e.g., subsets 150 ₁ and 150 ₂). Further, a subset of the micro-applicators may contain only one micro-applicator 110. Also, each of the micro-applicators can be a subset and thereby by individually addressable.

In some aspects of the present disclosure, a controller 122 (FIG. 2A) is included and enabled to individually address the at least one subset of micro-applicators 110 in the applicator array 102. Particularly, each of the micro-applicators 110 has a supply line 160 (FIG. 20) hi fluid communication with its reservoir 136 and the material source 8. Also, the controller 122 is configured to communicate with (i.e. address, receive, and send data) the power source 6, material source 8 and the at least one subset of micro-applicators 110 such that the at least one subset of micro-applicators 110 is individually addressable (e.g., switched on/off) at any given time. It should be understood that since the controller 122 can individually address the at least one subset of micro-applicators 110, different materials may be sprayed on the surface s′ from each applicator array 102. That is, the controller 122 can be configured to control which material M flows into the reservoir(s) of the at least one subset of micro-applicators 110 at any given time such that a coating C comprising a range of thickness, color, rheology, and the like on the surface s′ of the substrate S is provided. For example, the coating C in FIG. 2C includes a middle section c₁ formed by the subset 150 ₁ of micro-applicators 110 with a different thickness, viscosity, color, curing rate, etc., than and an outer section c₂ formed by the subset 150 ₂ of the two outer micro-applicators 110. In the alternative, or in addition to, a first coating or first layer 1 i of the coating C may be formed from a first material M₁ on the substrate S using a first subset of micro-applicators (e.g., subset 150 ₁) and a second coating or second layer 12 of the coating C may be formed from a second material M₂ over the first coating I₁ using a second subset of micro-applicators (e.g., subset 150 ₂). In some aspects of the present disclosure, the second coating I₂ is applied or formed on the first coating I₁ before the first coating I₁ is fully cured. It should be understood that the plurality of micro-applicators 110 can move across the surface S (x and/or y directions) such that the first and second coatings I₁, I₂ can be formed continuously across the surface s′ of the substrate S using only a subset of micro-applicators 110. This versatility decreases the consumption of material, energy, etc., of the paint spray system 2 over other high volume production environment paint systems.

While FIGS. 2A through 2C schematically depict the micro-applicators 110 positioned on the single plane 152, FIGS. 3A through 3C schematically depict the micro-applicators positioned on different planes. Particularly, and with reference to FIGS. 3A and 3B, the array plate 100 has two planes 152 ₁ and 152 ₂ arranged parallel but not coplanar to each other. One subset 150 ₄ of the micro-applicators 110 is positioned and aligned on the plane 152 ₁ and another subset 150 ₅ of the micro-applicators 110 is positioned and aligned on the plane 152 ₂. Accordingly, array plate 100 is faceted and has a stepped configuration. Also, and with reference to FIGS. 3A and 3C, the two planes 152 ₁, 152 ₂ of the array plate 100 are arranged non-parallel and nonplanar to each other. One subset 150 ₄ of the micro-applicators 110 is positioned and aligned on the plane 152 ₁ and another subset 150 ₅ of the micro-applicators 110 is positioned and aligned on the plane 152 ₂. Accordingly, array plate 100 is faceted and has an angled configuration with the angle not equal to zero degrees.

While planes 152 ₁ and 152 ₂ schematically depicted in FIG. 3C are convexly angled with respect to each other, it should be understood that planes concavely angled with respect to each other are within the teachings of the present disclosure. Also, in some forms of the present disclosure the array plate 100 is curved (concave or convex).

Referring now to FIG. 4, a method 200 of controlling application of material(s) to a substrate includes flowing a material into an ultrasonic spray nozzle comprising a plurality of micro-applicators at step 202 and independently addressing a subset of the plurality of micro-applicators at step 204. Independently addressing the subset of micro-applicators may include varying a pattern width of atomized droplets ejected from the plurality of micro-applicators at step 206; varying a flow rate of atomized droplets ejected from the plurality of micro-applicators at step 208; varying an angle that the atomized droplets are applied to a surface at step 210; ejecting different materials (e.g., M₁, M₂, M₃, or M_(n) shown in FIG. 1) at step 212, and combinations thereof. Non-limiting examples of materials ejected at step 212 include paint materials with different colors/pigments shown at 214, materials for different coating types (e.g., paint, sealant, adhesive, etc.) shown at 216, different materials for a given coating type (e.g., a paint basecoat material and a paint clearcoat material) shown at 218; and combinations thereof.

It should be understood from the teaching of the present disclosure that methods of controlling application of a material to a vehicle is provided. The method includes configuring a subset of an array of micro-applicators to eject a different material than the remainder of the micro-applicators. The different material may be a paint basecoat, paint a clearcoat, a flake containing basecoat, a non-flake containing basecoat, and the like. As such, the methods may include configuring a first subset of micro-applicators through which a first material is ejected and configuring a second subset of micro-applicators through which a second material is ejected. The first material may be ejected and applied onto a sag prone area of a vehicle followed by ejecting and applying the second material onto the sag prone area of the vehicle. For example, the first material is a one-component (1K) material and the second material is a rheology control agent. The rheology control agent may be an increased viscosity material or a catalyst material. Coupling the rheology control agent with the 1K material forms a two-component (2K) material that improves overall appearance and sag control of the 2K material on the sag prone area of the vehicle.

As described above the controller is enabled to individually address at least a subset of the micro-applicators. Thus, a plurality of micro-applicators through manual or automated control are configured and enabled to control (on/off/intensity): flow rate of material, material to be applied, number of materials, pattern width, other coating/painting variables, and combinations thereof. It should be understood that controlling material flow rate ejected from the plurality of micro-applicators controls droplet density and controlling density based as a function of part geometry enables uniform coverage and improves efficiency.

As described above, the present disclosure enables individually addressable micro-applicators and individually addressable arrays or subsets of arrays of micro-applicators. In some aspects of the present disclosure the individually addressable micro-applicators enable ejecting two or more different narrowly distributed atomized droplet sizes. For example, each micro-applicator and/or each subset of micro-applicators of a material applicator can eject a different material with its required or optimal atomized droplet size. In one non-limiting example, a first subset of micro-applicators of a material applicator applies (e.g., sprays) a basecoat material without metallic flake to a first area of a substrate and a second subset of micro-applicators of the material applicator applies a basecoat material with metallic flake to a second area of the substrate. Also, the first subset of micro-applicators ejects the basecoat material without metallic flake as atomized droplets with a first narrowly distributed droplet size and the second subset of micro-applicators ejects the basecoat material with metallic flake as atomized droplets with a second narrowly distributed droplet size that is different than the first average droplet size. As used herein, the phrase “narrowly distributed droplet size” refers to a droplet size distribution where greater than 90% of atomized droplets ejected from a micro-applicator have a droplet diameter within +/−10% of a mean droplet size of the atomized droplets ejected from the micro-applicator. In some aspects of the present disclosure, the droplet size distribution comprises greater than 95% of atomized droplets ejected from a micro-applicator having a droplet diameter within +/−5% of a mean droplet size.

In another non-limiting example, a first subset of micro-applicators of a material applicator applies a first color material to a first area of a substrate and a second subset of micro-applicators of the material applicator applies a second color material to a second area of the substrate. Also, the first subset of micro-applicators ejects the first color material as atomized droplets with a first average droplet size and the second subset of micro-applicators ejects the second color material as atomized droplets with a second average droplet size that is different than the first average droplet size. In still another non-limiting example, a first subset of micro-applicators of a material applicator applies a first layer material to a substrate and a second subset of micro-applicators of the material applicator applies a second layer material over the first layer material on the substrate. Also, the first subset of micro-applicators ejects the first layer material as atomized droplets with a first average droplet size and the second subset of micro-applicators ejects the second layer material as atomized droplets with a second average droplet size that is different than the first average droplet size.

It should also be understood that a paint booth using the composite ultrasonic applicators disclosed herein may provide improved efficiency and reduced cost. For example, such a paint booth may have:

-   -   airflow reduced from ˜100 ft/min. down to /60 ft/min.;     -   a side-draft booth in automated zones thereby providing a         smaller footprint for the paint booth;     -   reductions in dry-booth material consumption and a reduction or         elimination of wet-booth sludge system;     -   recirculation of air limited only by LEL (lower explosive level)         of solvent;     -   reduction of high pressure water blasting/cleaning of booth         grates;     -   reduced air consumption and associated reduction in energy used         to heat, humidify, and condition booth air;     -   reduced air consumption allowing reductions in abatement         equipment size; and     -   reduction in sludge waste removal and landfill cost.

As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.

When an element or layer is referred to as being “on,” or “coupled to,” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being Other words used to describe the relationship between elements should be interpreted in like fashion (e.g., “between” versus “directly between,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections, should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer and/or section, from another element, component, region, layer and/or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section, could be termed a second element, component, region, layer or section without departing from the teachings of the example forms. Furthermore, an element, component, region, layer or section may be termed a “second” element, component, region, layer or section, without the need for an element, component, region, layer or section termed a “first” element, component, region, layer or section.

Spacially relative terms, such as “outer,” “below,” “lower,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above or below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Unless otherwise expressly indicated, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, manufacturing technology, and testing capability.

The terminology used herein is for the purpose of describing particular example forms only and is not intended to be limiting. The singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

The description of the disclosure is merely exemplary in nature and, thus, examples that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such examples are not to be regarded as a departure from the spirit and scope of the disclosure. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. 

What is claimed is:
 1. A method of controlling application of at least one material onto a substrate comprising: configuring at least one array having a plurality of micro-applicators, wherein each of the plurality of micro-applicators has a plurality of apertures through which the at least one material is ejected and at least a subset of the micro-applicators is individually addressable to apply the at least one material to the substrate.
 2. The method according to claim 1, wherein the subset of micro-applicators is switched on and off to vary a pattern width of the at least one material onto the substrate.
 3. The method according to claim 1, wherein the subset of micro-applicators is switched on and off to vary a flow rate of the at least one material onto the substrate.
 4. The method according to claim 1, wherein a plurality of materials is ejected from the plurality of micro-applicators.
 5. The method according to claim 4, wherein the plurality of materials comprise different coatings selected from the group consisting of primer, basecoat, and clearcoat.
 6. The method according to claim 5, wherein at least one coating is applied to a previously applied coating before the previously applied coating is fully cured.
 7. The method according to claim 4, wherein a first subset of micro-applicators ejects a bulk basecoat material and a second subset of micro-applicators ejects a metallic flake material.
 8. The method according to claim 4, wherein a first subset of micro-applicators ejects a rheological additive while a second subset of micro-applicators ejects a paint material, wherein the rheological additive is mixed with the paint material during transport to the substrate.
 9. The method according to claim 1, wherein a plurality of paint colors is ejected from the plurality of micro-applicators.
 10. The method according to claim 9, wherein the plurality of paint colors is ejected at different times.
 11. The method according to claim 9, wherein the plurality of paint colors is ejected at different angles.
 12. The method according to claim 9, wherein a first subset of micro-applicators ejects a first color and a second subset of micro-applicators ejects a second color different from the first color.
 13. The method according to claim 1, wherein a first subset of micro-applicators is positioned on a first plane and a second subset of micro-applicators is positioned on a second plane different than the first plane.
 14. The method according to claim 13, wherein the second plane is not parallel to the first plane.
 15. The method according to claim 1, wherein the substrate is a vehicle body component and the at least one material is applied as a paint, an adhesive or a sealant.
 16. A method of controlling application of at least one material onto a surface of a vehicle comprising: configuring at least one array of a plurality of micro-applicators comprising a first subset of micro-applicators and a second subset of micro-applicators different than the first subset of micro-applicators, wherein each of the plurality of micro-applicators has a plurality of apertures through which the at least one material is ejected and the first subset of micro-applicators and the second set of micro-applicators are individually addressable to apply the at least one material to the surface of the vehicle.
 17. The method according to claim 16, wherein the first subset of micro-applicators and the second subset of micro-applicators are switched on and off to vary at least one of a pattern width, a flow rate of the at least one material, and the number of materials applied to the surface of the vehicle.
 18. The method according to claim 16, wherein a first material is ejected from the first subset of micro-applicators and a second material different than the first material is ejected from the second subset of micro-applicators.
 19. A material applicator for controlling application of at least one material on a substrate comprising: an array of micro-applicators comprising a first subset of micro-applicators and a second subset of micro-applicators different than the first subset of micro-applicators, wherein each of the micro-applicators comprises a micro-applicator plate, a plurality of apertures extending through the micro-applicator plate, a reservoir in fluid communication with the plurality of apertures; and at least one transducer in mechanical communication with each of the micro-applicator plates and configured to ultrasonically vibrate each of the micro-applicator plates; wherein the array of micro-applicators comprises a first subset of micro-applicators and a second subset of micro-applicators different than and individually addressable from the first subset of micro-applicators such that at least one material is applied to a substrate from the first subset of micro-applicators independently from the second subset of micro-applicators.
 20. The material applicator of claim 19, wherein the first subset of micro-applicators is positioned on a different plane than the second subset of micro-applicators. 